Replace front ABS sensor in 93 4x4 explorer

[Watchman]

I just had the front outer u-joints replaced and the ABS sensors were so bad that they had to be destroyed in the repair. The shop was good enough to tie wrap the wires up so I could repair them myself. The problem was that no parts stores in our area had any in stock and they had at least a week lead time. So I told the shop owner I would replace them myself. I feel I can find decent ones on the internet. But I need a thread to guide me. Is there one I can get directed to with a step by step breakdown ?

 

[arco777]

I have never had much luck separating the sensors from the spindles. If you can't successfully replace them I wouldn't worry about it too much. The first gen Explorer's ABS system is terrible in any condition except perhaps a wet road. I know in the snow it has almost killed me several times. Just early ABS systems for you. I disabled my ABS and never looked back. The ABS system being inop will not affect any other systems so as long as the warning light doesn't bother you (or remove the bulb) it won't hurt anything.

 

[Anime]

Actually, the shop messed up by failing to just disconnect the ABS sensor wires at the front of the frame and leaving the sensors in the steering knuckles when replacing the ball joints.

In any case, you can replace the sensors by taking the bolt out of the back of the sensor, and using a punch or steel rod and a hammer to pound it backwards. It might also help to soak it with some spray penetrant as the metal part of the sensor tends to rust to the knuckle.

This is easier with the spindle removed from the steering knuckle, which gives you easy access to the sensor, but it's easier in some ways with the knuckle mounted to the vehicle so you're not pounding on the sensor with the knuckle just sitting on the floor.

Just keep at it with a big enough hammer once the bolt is out and it'll eventually start moving, just keep it up and take breaks if you need to.

Once it's out, clean up the sensor hole, insert the new sensor, and bolt it on. You can also stick the sensor in the freezer for a while to make it shrink a tiny bit, making it easier to stick in the knuckle, assuming the knuckle is slightly warm.

 

[BKennedy]

If the 94 is the same as the 93 ABS, there are two bolts. One holds the electrical plug, and the other the sensor. The spindle will not come off with the sensor in place as it wraps around the front of the spindle. The electrical comes off the back and the sensor gets pushed from back to front through the knuckle, or front to back, I can't remember which.
Also, you can't press out the ball joints with the axle in place, so you have to take the spindle off first because the axle is held in place by the spindle.
I just took mine apart a few weeks ago in order to start an SAS. Why don't you PM me about the sensors.

 

[Watchman]

arco777 - I appreciate the advice to disconnect - but I can remember a time when I was driving into Oakland on I880 and it was raining. I was talking to my wife and then I looked up and there was four lanes of traffic stopped right in front of us. Well, I hit the brakes and they pulsed as they slowed down the vehicle, and we stopped inches from the vehicle in front of us. So, that's why I need the functionality. It proved it to me.

Anime - It was the universal joints that were replaced, not ball joints. I do have a question - in your picture, did you have to removed the rotor and everything in front of it ? I was hoping to just remove the tire and turn the wheel end. Then have access to the sensor. What do I need to remove at a minimum to replace the sensor ?

BKennedy - what is PM ?

 

[BKennedy]

Anime - It was the universal joints that were replaced, not ball joints. I do have a question - in your picture, did you have to removed the rotor and everything in front of it ? I was hoping to just remove the tire and turn the wheel end. Then have access to the sensor. What do I need to remove at a minimum to replace the sensor ?

BKennedy - what is PM ?

PM is a private message when you don't want to discuss things on a public forum. You just click on the person who you want to PM's moniker, and it gives you options. Pick "send private message". I want to offer to send you my old sensors, wires, bolts, etc.. for the cost of a flat rate box. They are not pretty, but they work. The PM is to discuss the details.

To get to the sensor, you have to remove the brakes (which is easy) and the rotors (which is not hard, but time consuming). While you were having the u-joints replaced, did they do any routine maintenance? This would be a good time to repack the wheel bearings.

 

[Anime]

If the 94 is the same as the 93 ABS, there are two bolts. One holds the electrical plug, and the other the sensor. The spindle will not come off with the sensor in place as it wraps around the front of the spindle. The electrical comes off the back and the sensor gets pushed from back to front through the knuckle, or front to back, I can't remember which.

What?

One short bolt holds the sensor on but also threads through to the spindle, the smaller bolt holds the sensor shield on.

The spindle is easily removed (with a spindle socket and slide hammer, at least) with the sensor in place once both bolts are removed.

The sensor gets pushed through the back to install, and pushed from the front to the back to remove.

Anime - It was the universal joints that were replaced, not ball joints. I do have a question - in your picture, did you have to removed the rotor and everything in front of it ? I was hoping to just remove the tire and turn the wheel end. Then have access to the sensor. What do I need to remove at a minimum to replace the sensor ?

You'll have to pull off the caliper, and remove the the rotor, to get access to the sensor from the front. You'll never be able to pull it out from the back, since it tends to rust itself to the knuckle - it's in there good.

Heres the whole thread the pics are from so you can see what's involved:

http://www.explorerforum.com/forums/showthread.php?t=218254

 

[BKennedy]

What?

One short bolt holds the sensor on but also threads through to the spindle, the smaller bolt holds the sensor shield on.

The spindle is easily removed (with a spindle socket and slide hammer, at least) with the sensor in place once both bolts are removed.

The sensor gets pushed through the back to install, and pushed from the front to the back to remove.
http://www.explorerforum.com/forums/showthread.php?t=218254

Your right. I just looked at the pile of parts in my side yard, and there it was. All you need to remove is the smaller bolt that holds the shield on to get the spindle off. I guess I was not paying as much attention since I was not planning on putting it back.

 

[Watchman]

Thanks guys for all the pics. All I had to do is jack up the front end, then turn the wheels to access each side. I was able to re-use the drivers side sensor, but had to change the pass. The installation was easy, maybe 30 min. Re-routing was easy - just follow the clipping points. All works well now.

 

[Anime]

Thanks guys for all the pics. All I had to do is jack up the front end, then turn the wheels to access each side. I was able to re-use the drivers side sensor, but had to change the pass. The installation was easy, maybe 30 min. Re-routing was easy - just follow the clipping points. All works well now.

You're saying you were able to pull the sensor out of the spindle from the back without pulling the wheel/rotor and pounding it out?

Should have made a video of that, that'd make some jaws drop around here after what lots of people have gone through replacing theirs.

 

[Watchman]

I wish I could have video'd that, but it wasn't that hard. I took the truck for a drive and the ABS light is off now. But, the brake pedal pulses bad when you come to the end of the stop. So, I am going to replace the pass side when the other sensor comes in. Hopefully this will stop the pulsating pedal when you come to the end of the stop.

 

[Bikerdoug]

Actually, the shop messed up by failing to just disconnect the ABS sensor wires at the front of the frame and leaving the sensors in the steering knuckles when replacing the ball joints.

In any case, you can replace the sensors by taking the bolt out of the back of the sensor, and using a punch or steel rod and a hammer to pound it backwards. It might also help to soak it with some spray penetrant as the metal part of the sensor tends to rust to the knuckle.

This is easier with the spindle removed from the steering knuckle, which gives you easy access to the sensor, but it's easier in some ways with the knuckle mounted to the vehicle so you're not pounding on the sensor with the knuckle just sitting on the floor.

Just keep at it with a big enough hammer once the bolt is out and it'll eventually start moving, just keep it up and take breaks if you need to.

Once it's out, clean up the sensor hole, insert the new sensor, and bolt it on. You can also stick the sensor in the freezer for a while to make it shrink a tiny bit, making it easier to stick in the knuckle, assuming the knuckle is slightly warm.

You're on the money, and THANKS MUCH for this post. I might add (once I bit the bullet and took the spindles off), NOW is a good time to check/replace/repair your front disk brake system including the condition of the rubber hydraulic brake hose going to the caliper. I found the hoses on my old reliable '93 cracked, and replaced them. Didn't really need new pads, but since I was already there, went ahead and replaced both the pads and the OE calipers. Checked, cleaned and re-greased the wheel bearings as well and replaced the shocks, too, since everything was handy. ---I USED A GOOD QUANTITY OF PB BLASTER AND DEEP CREEP ON THE ABS SENSORS (inside and outside the spindle) AND THE BRAKE HOSE CONNECTOR TO HEAD OFF PROBLEMS AND IT WORKED (just FYI). Yes, I ended up doing all that stuff. Didn't spend all that much on parts - most expensive thing was the mail order ABS sensors - but of course it took some more time. Like everything else, just biting the bullet and starting was the worst part. Hardest single thing was just getting the wheels off - had to use a 24" extension to break the lug nuts loose, thanks to my local tire installer - that was a "2 beer job" by itself.

 

[Centaurious]

Sounds like the hole for the sensor needs a real good cleaning/scraping and coated with anti seize before installing a new sensor.